Fundamentals and preliminary sizing of

sections and joints

Objectives:
• Overview of section and joint structural behaviour
• To outline the design and sizing approach

Characteristics of thin walled sections:

a. Open section – thin sheet metal is formed with a
discontinuity
b. Closed section – the section forms a complete loop
Open sections
- the angle section (a) is not a suitable structural member because bending
will occur both axes. In addition stress distribution is very asymmetric and
results in large parts of the section being under stresses.
- the z section (b) has similar undesirable characteristics
- the channel section © is a suitable structural section and used in
commercial vehicle chassis and body structures. However, it is less stiff
about Y-Y axis.
- the wide flange results in a low stress at which
buckling occurs.
Adding a lip to the channel (d) can improve in
buckling stress
-the hat section (e) has good bending provided
2b2=b1
Open section
The major limitation of all open section is their lack of torsional
stiffness due to very low polar second moment of area:
Section a: Jx = (a + b)t3/3
Section b: Jx = (b1 + b2 +d)t3/3
Section c: Jx = (2b + d)t3/3
Section d:Jx = (2d1 +d + 2b)t3/3
Section e:Jx = (b1 + 2b2 + 2d)t3/3

Theta = TL/GJx
 Closed sections
• The main advantages of all closed sections
is that
they have greatly improved torsional
stiffness.
• the closing of the section by the spot weld
• polar second moment of area: Jx = 4A2t/s
where A(a)=(b1-2b2)d+4(b2-b3)t
s = 2(b1-2b3)+2d+4(b2-b3)
Passenger car sections
• Actual passenger car sections are
more complex in detail profiles.
• When calculating stress,
evaluation of section moments of
area and torsion constant can be
found using modern CAD methods.
• Structural properties, practical
installation and functional
requirements are the criteria for
choosing types of section.
Example of initial section sizing
Front floor cross-beam

Bending moment
M = K 2l1 − F fp l2

Stress due to bending

f = My / I

Shear stress
τ = K 2 Ay / zI
The A-pillar
• The A-pillar has large bending loads when structure
is loaded in torsion.
• Bending moment about X-X axis:
Mx = Q1h / 4
And bending stress:

Fbx = M x b / I xx 2
The normal force gives rise to a bending moment:
M y = (nQ2 sin α )h / 2 cos α
will cause a bending stress:
f by = M y d / I yy 2
Direct force into the pillar giving s stress:
f c = nQ2 cos α /( 2b + 2d )t
f total = f c + f by + f bx
Engine longitudinal rail
This component is subjected to shear forces
and bending moments.

Due to high shear and bending moments, deeper

section is needed and leads to larger depth, d.

This section should also be designed to absorb

energy in frontal impact
Sheet metal joints
• If a moment is applied it will cause tension and
compression. The net result is there cannot be
any significant bending stiffness.
• Vertical shear force is carried by the side
flange. If the side flange is removed, the top/
bottom flanges will be ineffective to resist the
normal force and hence they will distort.
• Horizontal shear force will result in opposite
condition as shown above.
• If the cross-beam is subject to a torsion
the shear flow around the section is:
q = T / 2 A = T / 2d ' v '
Two important rules for designing joints:
a) Avoid out-of-plane bending on thin sections
b) Load thin sections with in-plane bending
and shear.
Spot welds
Spot weld and connector patterns

y = (3 y1 + 3 y2 ) / 8
x = (2 x1 + 3 x2 ) / 8
FE1 / r1 = FE2 / r2 .......FE / rn = K
n
n
∑ FEn rn = M • Spot weld 7 has very
1 little load while spot
n
2
∑ Kr n = M weld 3 experience heavy
load.
1
M • Some repositioning could
K= be made to redistribute
n
∑ rn 2 loads
1
Spot welds along a closed section
τ = q / t = T / 2 At = T / 2d (b1 − 2b2 )t
N = qL / Fs No of spots required

Pe = Kπ 2 EI / L2 Buckling load, K=3.5

fcr = Pe / A = 3.5π 2 EAk 2 / Ap 2

f b = Md / 2 I Actual stress due BM

Pitch requirements to prevent buckling

p = (3.5 Eπ 2t 2 / 12 f b )
Shear Panels: Roof
Roof is the largest panel in a passenger car and under the torsion. This may lead
to buckle issue.

The shear stress at which the panel buckles is given by:

τ = KE (t / b) 2 K=buckling coefficient

Investigation made into a roof panel 980mm x 1250mm x 1mm x 2425mm

(curvature), the stress cause buckling is 13.88N/mm2 – 4x than applied shear stress

Another approach to designing roof and other panels is to consider the vibration
characteristics. ESDU 75030 can be used to predict panel vibrations. Range of
frequency from 4 to 33 Hz.

Low frequency vibrations will cause ride and comfort problems.